- If necessary, perform the following steps:
1.1. | Install NEW seals to the thermostats. |
1.2. | Install the thermostats. |
Notice: Refer to Fastener Notice in the Preface section.
1.3. | Install the thermostat cover and bolts. |
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
1.4. | Install a NEW O-ring seal to the thermostat bypass pipe. |
1.5. | Install the thermostat bypass pipe to the thermostat housing. |
- Install a NEW thermostat bypass pipe to water pump O-ring seal.
- Install the thermostat housing using NEW gaskets.
- Install the thermostat housing bolts and nuts
Tighten
Tighten the bolts/nuts to 21 N·m (15 lb ft).
- Install the water pump inlet pipe bolts.
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
- Install the cooling fan pulley. Refer to
Cooling Fan Pulley Replacement
.
- Install the fuel line bracket bolt at the thermostat housing crossover.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Install the turbocharger coolant return pipe hose.
- Position the turbocharger coolant return pipe hose clamp.
- Install the EGR coolant pipe with O-ring seal to the crossover.
- Install the EGR coolant pipe bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Position the EGR hose clamp at the EGR coolant pipe.
- Install the water outlet. Refer to
Water Outlet Tube Replacement
.
- Install the oil fill tube. Refer to
Oil Filler Tube Replacement
for the 6.6L (LLY) engine.
- Position the generator bracket.
- Install the generator bracket bolts.
Tighten
Tighten the bolt to 50 N·m (37 lb ft).
- Install the idler pulley.
Tighten
Tighten the bolt to 43 N·m (32 lb ft).
- Install the heater outlet hose bracket bolt to the generator bracket.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Position the A/C compressor/power steering pump bracket.
- Install the A/C compressor/power steering pump bracket bolts.
Tighten
Tighten the bolt to 46 N·m (34 lb ft).
- Position the generator positive cable and the junction block bracket.
- Install the battery positive cable junction block to power steering pump bolt (1).
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- Install the clip holding the positive cable to the engine front cover.
- Install the positive cable to the generator.
- Install the generator positive cable to generator nut.
Tighten
Tighten the nut to 9 N·m (80 lb in).
- Connect the ECT sensor electrical connector.
- Connect the generator electrical connector.
- Position the A/C compressor, with the hoses attached.
- Install the A/C compressor bolts.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Connect the A/C cut out switch electrical connector.
- Connect the A/C compressor clutch electrical connector (5).
- Install the drive belt. Refer to
Drive Belt Replacement
for the 6.6L (LLY) engine.
- Install the upper fan shroud. Refer to
Engine Coolant Fan Upper Shroud Replacement
.
- Connect the negative battery cables. Refer to
Battery Negative Cable Disconnection and Connection
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Install the intake manifold cover. Refer to
Intake Manifold Cover Replacement
for the 6.6L (LLY) engine.